INSPECTION

CURRENT IDEAL
AREA ITEM ASSEMBLY PROCESS PRODUCTION QA CHECKING AREA ITEMASSEMBLY PROCESS PRODUCTION QA CHECKING REMARKS
ASSEMBLY 1 PCB DEPANELING 1 PCB DEPANELING

AC AND DC WIRE SOLDERING AC AND DC WIRE

SOLDERING

2 2.1 AC SOLDERING 2.1 AC SOLDERING

IPQC CHECK EVERY 2 HOURS IPQC CHECK EVERY 2 HOURS TO ADD VISUAL INSPECTION IN
(10PCS SAMPLING SIZE) 2 (20PCS SAMPLING SIZE) SOP
2.2 DC SOLDERING 2.2 DC SOLDERING

3 UPCASE

4 ADHESIVE DISPENSING 3 UPCASE

5 DOWN CASE ASSEMBLY ADHESIVE DISPENSING

4 IPQC CHECK EVERY 2 HOURS TO ADD VISUAL INSPECTION IN
NO SPECIFIC/ (20PCS SAMPLING SIZE) SOP
6 FUNCTIONAL TESTING ASSIGNED IN VISUAL
INSPECTION ONLY
7 HI-POT TESTING FROM PRODUCTION 5 DOWN CASE
(100% VISUAL)

8 PRESSING IPQC CHECK EVERY 2 HOURS 6 FUNCTION TESTING

(20PCS SAMPLING SIZE)

BURN-IN 9 BURN IN PRESSING PACKER SHOULD DO THE 100%

7 IPQC CHECK EVERY 2 HOURS INSPECTION
(20PCS SAMPLING SIZE) TO ADD VISUAL INSPECTION IN
PACKAGING 10 FUNCTIONAL TESTING VISUAL INSPECTION 100% SOP
IPQC CHECK EVERY 2 HOURS CHECKSHEET WILL BE DONE BY
11 LABELING BURN IN 8 BURN IN (PARAMETER) BURN IN LINE LEAD
IPQC CHECK EVERY 2 HOURS
(20PCS SAMPLING SIZE)
12 WHITE BOX 9 ATE TESTING

13 CARTON BOX 10 LABELING

LABEL SHOULD BE CHEKKED

VISUAL INSPECTION 100% BEFORE ATTACHMENT
IPQC CHECK EVERY 2 HOURS TO ADD VISUAL INSPECTION IN
(20PCS SAMPLING SIZE) SOP

PACKAGING 11 WHITE BOX WHITE BOX SHOULD BE

CHECKED BEFORE USING
TO ADD VISUAL INSPECTION IN
VISUAL INSPECTION 100% SOP

12 CARTON BOX OBA INSPECTION

PACKER SHOULD DO THE 100%
INSPECTION FOR THE OUTER
BOX
VISUAL INSPECTION 100% TO ADD VISUAL INSPECTION IN
SOP
EQUIPMENT PARAMETER CHECKSHEET EQUIPMENT PARAMETER CHECKSHEET
CURRENT IDEAL
AREA ITEM ASSEMBLY PROCESS PRODUCTION QA CHECKING AREA ITEM ASSEMBLY PROCESS PRODUCTION QA CHECKING
1 PCB DEPANELING 1 PCB DEPANELING

AC AND DC WIRE SOLDERING AC AND DC WIRE SOLDERING

2 2.1 AC SOLDERING 2 2.1 AC SOLDERING

2.2 DC SOLDERING 2.2 DC SOLDERING

3 PCBA INSERTION 3 PCBA INSERTION

ASSEMBLY ASSEMBLY
4 ADHESIVE DISPENSING 4 ADHESIVE DISPENSING

5 UP CASE LOCKING 5 UP CASE LOCKING

6 FUNCTIONAL TESTING no checklist no checklist 6 FUNCTIONAL TESTING

7 HI-POT TESTING no checklist no checklist 7 HI-POT TESTING

should have checklist
8 PRESSING no checklist with checklist -IPQC 8 PRESSING (once per day/change with checklist- include in
model) IPQC checking every 2 hours
BURN-IN 9 BURN IN no checklist no checklist BURN-IN 9 BURN IN

10 FUNCTIONAL TESTING no checklist with checklist-included 10 ATE TESTING

in IPQC checklist
11 LABELING 11 LABELING
PACKAGING PACKAGING
12 WHITE BOX 12 WHITE BOX

13 CARTON BOX 13 CARTON BOX

LASER 14 LASER no checklist with checklist LASER 14 LASER with checklist (once per with checklist- include in
day/change model) IPQC checking
ITEM NO. PLAN DETAILS NEEDED REMARKS
- checking of raw materials based on technical drawing -PROCEDURE - All incoming raw materials should be inspected based
requirements -WI on AQL sampling plan
- checking of semi finished parts -LOCATION - Need to request drawing per materials for reference
-check appearance and dimension -DRAWING/TDS (to be requested to
1 SET-UP INCOMING INSPECTION - checking of material number (pcba/down case/up case/cord) supplier)
-COC
-SUPPLIER INSPECTION DATA

- checking of appearance every two hours each process

- checking of parameter setting in equipment (used in testing) PROCEDURE
every two hours
2 IMPROVE IN-PROCESS INSPECTION - checking of labels vs.actual (using matrix of model design) WI every change model/start of the shift
- checking of material number used (pcba/down case/up TDS
case/cord) specially every change model

- checking of appearance every box

SET-UP OUTGOING INSPECTION OR - checking if white box P/N is the same with Outer carton box PROCEDURE Outgoing parts should be inspected based on AQL
3 and outer carton box label detail. WI
OUT OF THE BOX INSPECTION -Checking if quantity of white box is tallied with the carton box PACKAGING STANDARD sampling plan.
quantity

- DCC
-CONTROL OF RECORDS
4 PROVISION OF PROCEDURE - INCOMING PROCEDURE/IN-PROCESS
PROCEDURE/OUTGOING PROCEDURE
-HANDLING OF NON-CONFORMITY

-Incoming Checksheet-done
IMPROVEMENT/GENERATION OF -In-process Checksheet
5 CHECKLIST/CHEEKSHEET -OBA Checksheet

- Bill of Materials
-Function Test Matrix
6 PROVISION OF MATRIX -Design of each model Note: Need to have data for the ATE testing.
-internal partnumber vs. customer part number
-Packaging Standard

7 AREAS FOR IMPROVEMENT REFER TO OFI SHEET

INSPECTION PROCESS

Inspection Reference Materials Procedures Needed Needed equipment Sampling Size Manpower Frequency
INPSECTION PROCESS
Incoming Inspection
Data Sheet Procedure Magnifying Lamp

QA INCOMING QUALITY Supplier Inspection Data Working Instruction Caliper Every batch
AQL 0.65 level 2 At least 2 person received
INSPECTION Technical Drawing Ruler
Work Instruction
GU Sample/reference sample

Work Instruction In-Process Quality Inspection

QA IN-PROCESS QUALITY GU Sample/reference sample Working Instruction Naked eye 5pcs at least 1 each line every two hours
INSPECTION

Work Instruction Working Instruction

PRODUCTION VISUAL GU Sample/reference sample
Naked eye 100% operator every batch
INSPECTION (ASSEMBLY)

Work Instruction Working Instruction

PRODUCTION VISUAL GU Sample/reference sample
Naked eye 100% white box operator every batch
INSPECTION (PACKAGING)

Work Instruction Outgoing Inspection

QA OUTGOING GU Sample/reference sample Working Instruction
Naked eye 5pcs at least 1 each line every batch
INSPECTION/OBA INSPECTION
 QA ORGANIZATIONAL CHART

SIR JERRY
(VP)

BIENGBIENG
CHONG
(QA HEAD)

TERESA
PUNZALAN
(QA JR SUP.)

INCOMING QC VACANT IN-PROCESS QC OUTGOING /OBA

IQC 1- VACANT A1- ARLO P8- VACANT

IQC 2- VACANT A2- VACANT P10-VACANT
A3- RUSSEL P13-VACANT
P8- CONNIE P14-VACANT
P10-VALERIE

P13- REYMARK
P14- VACANT
 PLAN

ACTUAL TIMELINE FOR ISO CERTIFICATION

FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER
NO ACTIVITY ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww5 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww5 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww5
PLAN
1
Kick-off meeting to officially announce to the
organization the plan for certification. ACTUAL

Start selection of certifying body (TUV SUD,TUV PLAN

2 RHEINLAND) ACTUAL

Start establish of ISO documents

PLAN
3.1 Document Control ACTUAL
PLAN
3.2 Contol of Records ACTUAL
PLAN
3.3 Internal Audit ACTUAL
3

PLAN
3.4 Control of Non-Conforming Product ACTUAL
PLAN
3.5 Corrective Action Procedure ACTUAL
PLAN
3.6 Preventive Action Procedure ACTUAL

Ensure the management establish:

PLAN
4.1 Quality Policy ACTUAL
PLAN
4
4.2 Quality Objectives ACTUAL
PLAN
4.3 Organizational Chart ACTUAL

4.4 Quality Manual

PLAN
5
After establishing the procedure, it needs to be
implemented before the certification (3 months minimum) ACTUAL
PLAN
6
Create a team of internal auditors. They should
be trained ACTUAL

Before the certification, need to conduct:

PLAN
7 7.1 Internal Audit ACTUAL
PLAN
7.2 Management Review ACTUAL
PLAN
8
Before the certification, need to arrange pre-
certification audit to the certifying body. ACTUAL
PLAN
9
Take action to the findings from pre certification
before the certification period ACTUAL
Certification audit: Before the audit need to PLAN
10 submit the documents for auditors examination ACTUAL
before the actual audit
 AVAILABLE
ON-GOING
NOT YET AVAILABLE
ISO DOCUMENTS NEEDED
FEBRUARY MARCH APRIL
1. PROCEDURE STATUS DOC NO. ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4

1.1 QA
1.1.1 Incoming Quality Control Inspection Procedure
1.1.2 In-Process Quality Control Inspection Procedure
1.1.3 Outgoing Quality Control Inspection Procedure
1.1.4 Document Control System Procedure
1.2 PRODUCTION
1.3 HR
1.4 FINANCE
1.5 WAREHOUSE
1.6 LOGISTIC/IMPEX
1.7 INVENTORY/PLANNING
1.8 PURCHASING
FEBRUARY MARCH APRIL
2. WORKING ISNTRUCTION STATUS DOC NO. ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4

2.1 PRODUCTION PROCESS

2.1.1 Assembly Process
PCB Depaneling
AC and DC Wire Soldering
Upcase
Adhesive Dispensing
Downcase
Function Testing
Hi-Pot Testing
Pressing
FVI
2.1.2 Burn -in Process
2.1.3 Laser Process
2.1.4 Packaging Process
Function Testing
Labeling
FVI
White Box
Carton Box
2.2 QA PROCESS
2.2.1 Incoming Quality Control Inspection
2.2.2 In-Process Quality Control Inspection
2.2.3 Outgoing Quality Control Inspection
2.3 RECEIVING PROCESS
2.4 SHIPPING PROCESS
 FEBRUARY MARCH APRIL
3. CHECKSHEET/REPORT/FORMS STATUS DOC NO. ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4

2.1 PRODUCTION PROCESS

2.1.1 Assembly Process
Function Testing
Hi-Pot Testing
Pressing
2.1.2 Burn -in Process
2.1.3 Laser Process
2.2 PRODUCTION MONITORING REPORT
2.2.1 Material Status Label Form
2.2.2 WIP Details Form
2.3 QA PROCESS
2.2.1 Incoming Quality Control Inspection
2.2.2 In-Process Quality Control Inspection-ASSEMBLY
2.2.3 In-Process Quality Control Inspection-PACKAGING
2.2.4 In-Process Quality Control Inspection-BURN-IN
2.2.5 Outgoing Quality Control Inspection
2.3 RECEIVING PROCESS
2.4 SHIPPING PROCESS
FEBRUARY MARCH APRIL
4. LABELS STATUS DOC NO. ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4

4.1 PRODUCTION PROCESS

4.1.1 Reject Tag
4.1.2 Hold Tag
4.1.3 Parts for repair
4.1.4 Work In Process
FEBRUARY MARCH APRIL
5. STAMP STATUS DOC NO. ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4 ww1 ww2 ww3 ww4

5.1 QA STAMP
5.1.1 IQC PASSED
5.1.2 IQC REJECT
5.1.3 QA PASSED
5.1.4 QA REJECT
5.2 DCC STAMP
5.2.1 MASTER COPY
5.2.2 CONTROLLED COPY
5.2.3 UNCONTROLLED COPY
5.2.4 OBSOLETE COPY
 OPPORTUNIY FOR IMPROVEMENT (PPE AND SIGNAGES)
ITEM ASSEMBLY PROCESS COMMENTS FREQUENCY
GLOVES WRIST STRAP BLACK HAIR NET
1 PCB DEPANELING USE OF GLOVES
2 AC AND DC WIRE SOLDERING USE OF GLOVES
2.1 AC SOLDERING
2.2 DC SOLDERING
3 UDOWN CASE USE OF GLOVES
4 ADHESIVE DISPENSING USE OF GLOVES TO PREVENT DISTRACTION DURING once per
day/change modelOPERATION DUE TO
5 UP CASE FOR SAFETY REQUIREMENTS FOR ESD REQUIREMENTS STRONG EXHAUST FAN
6 FUNCTION TESTING
7 PRESSING
8 BURN IN SAMPLE STATION LABEL
9 ATE TESTING
10 LABELING
11 WHITE BOX
12 CARTON BOX

SUGGESTION:
USE OF GLOVES FOR SAFETY REQUIREMENTS AND TO AVOID SCRATCHES/ MOIST FROM BARE
1 HANDS
2 WRIST STRAP TO BE USED FOR ESD REQUIREMENTS TO BE USED AS REFERENCE OF EACH LINE FOR
PROCESS SIGNAGE
HAIRNET -HAIR SHOULD BE TIE/WITH CAP/HAIRNET TO AVOID FALL OF HAIR INSIDE THE
3 PRODUCT TO BE USED AS REFERENCE OF EACH LINE FOR THE PRODUCTION
DETAILS BEING RUN FOR THE DAY
4 WORK IN PROCESS LABEL TO BE USED AS REFERENCE OF EACH LINE FOR THE

5 STATION SIGNAGES

6 KANBAN-PUTTING OF SIGNAGES IN THE BOX STORE IN DIFFERENT LOCATION (STATUS LABEL)

KANBAN
 MANUAL PROCEDURE
HK-M-XXX-XXX HK-P-XXX-XXX

SERIES NUMBER SERIES NUMBER

SECTION CODE SECTION CODE

DEPARTMENT CODE DEPARTMENT CODE

WORK INSTRUCTION FORMS

HK-WI-XXX-XXX HK-DCF-XXX-XXX

SERIES NUMBER SERIES NUMBER

SECTION CODE SECTION CODE

DEPARTMENT CODE DEPARTMENT CODE

 DEPARTMENT CODE AREAS CODE
HR H
ACCOUNTING/FINANCE F
PURCHASING PU
INCOMING I
QUALITY CONTROL Q IN-PROCESS N
OUTGOING O
ASSEMBLY A
PACKAGING P
PRODUCTION P
LASER L
BURN-IN B
LOGISTIC L SHIPPING S
PLANNING PL

DEPARTMENT CODE
HR H
ACCOUNTING/FINANCE F
PURCHASING PU
QUALITY CONTROL Q
PRODUCTION P
LOGISTIC L
PLANNING PL
QC STAMP PASSED AND REJECT (IN-PROCESS AND OUT-GOING)

QC PASSED QC REJECT
01 01

Date: Date:

EXAMPLE:
01 CONNIE
02 RUSSEL
03 ARLO

DCC STAMP

HK

HK

HK

HK
 HK

HK

HK
IQC PASSED AND REJECT (INCOMING INSPECTION)

IQC PASSED IQC REJECT

01 01

Date: Date:
DOCUMENT STAMP SAMPLE PURPOSE

Original document signed by

authorized personnel.
MASTER COPY
Master copy bear no Controlled
Copy stamp.

Document which requirements

for its establishment, approval,
issue,revision, distribution,
CONTROLLED COPY
maintenance,use,storage,securi
ty,obsolescence and disposal is
defined.

Document which maintenance,

use,storage,
UNCONTROLLED
security,obsolescence and
COPY
disposal is not define and needs
no updating.

Documents that are not yest

controlled and use as reference
REFERENCE COPY while on-going
establishment/revision of
document

Authorized documents that

relate to the
EXTERNAL DOCUMENT quality/environmental system
which are not established within
the organization

Document that has been

OBSOLETE COPY superseded. Copies maintained
 Document that has been
OBSOLETE COPY superseded. Copies maintained
for the purposes

Temporary Document shall be

valid for one (1) month and can
TEMPORARY
only be renewed if there will be
DOCUMENT
valid reasons as agreed by
concerned division/section.
Quality issue Guidelines:
Step 1: get defect percentage from population of 30 or more samples (per line if running the same model and PO)
Step 2: do process mapping and commonality analysis and provide material detail (model/PO/location)
Step 3: get samples of light and severe defects
Step 4: production to segregate affected parts while waiting for disposition (if material related meaning with common
Step 5: Show sample to S’Jerry
Step 6: S’Jerry to inform China for disposition
Step 7: Execute management disposition

Plan on setting up quality system:

Step 1: Complete all needed documentation
-        Work instructions
-        Inspection checklist
-        Procedures
-        Quality reports
-        Production house rules
-        6S
Setp 2: review and approval on the suggested changes
Step 3: Training
Step 4: Implementation
he same model and PO)
/PO/location)

ated meaning with common location)

 PLAN
ACTUAL

ACTIVITY FEBRUARY
TRAINING MATERIALS PREPARATION 20-Feb 22-Feb 23-Feb
1 PRESENTATION (POWER POINT)

2 COMPLETION OF WORK INSTRUCTION (SOP)

2.1 PCB Depaneling AVAILABLE

2.2 AC and DC Wire Soldering AVAILABLE

2.3 Upcase

2.4 Adhesive Dispensing AVAILABLE

2.5 Downcase

A 2.6 Function Testing AVAILABLE

2.7 Hi-Pot Testing AVAILABLE

2.8 Pressing AVAILABLE

2.9 Burn-in

3 COMPLETION OF CHECKSHEET

3.1 Incoming Inspection Checksheet

3.2 In-Process Inspection Checksheet AVAILABLE

3.3 Out going Inspection Checksheet

4 COMPLETION OF PROCEDURE

4.1 Incoming Quality Control Procedure

4.2 In-Process Quality Control Procedure

4.3 Outgoing Quality Control Procedure

4.4 Equipment Procedure (SOP)

QA PERSONNEL SELECTION FOR TRAINING
B
1 FIVE PERSON FOR QA TRAINING AVAILABLE
 ROOM TRAINING
1 QUALITY OVERVIEW

2 FAMILIARIZATION OF THE PARTS

3 DEFECTS FAMILIARIZATION

4 DISCUSSION OF CHECKSHEET
C
5 QA RESPONSIBILITY

6 CHECKING FREQUENCY

7 SAMPLING INSPECTION PLAN

8 AUDITING

9 OUT OF CONTROL ACTION PLAN

ACTUAL TRAINING

D 1 VISUAL INSPECTION

2 FUNCTION TESTING

SETTING-UP QUALITY CONTROL IN PRODUCTION FLOOR

FEBRUARY MARCH
24-Feb 25-Feb 26-Feb 1-Mar 2-Mar 3-Mar 4-Mar 5-Mar
6-Mar
 PROCESS INCOMING QUALITY CONTROL DEPANELING

INSPECTION OF RAW
JOB DESCRIPTION
MATERIALS

SUPPLIER DATA/TECHNICAL
DOCUMENTS TO BE
DATA SHEET /WORK
USED AS REFERENCE
INSTRUCTION

CHECKSHEET TO BE
INCOMING CHECKSHEET
USE
 PROCESS FLOWCHART

AC/DC
DEPANELING PROD VISUAL UPCASE ADHESIVE
SOLDERING

PRODUCTION PROCESS (ASSEMBLY)

TECHNICAL DATA SHEET AND WORK INSTRUCTION

PRODUCTION DAILY REPORT FORM

CHART
IN-PROCESS
DOWNCASE TEST PRESS PACK QUALITY
CONTROL

PRODUCTION
OCESS (ASSEMBLY) QUALITY
CHECK

TECHNICAL
ORK INSTRUCTION PER PROCESS
DATA SHEET

IPQC
LY REPORT FORM
CHECKSHEET
IN-PROCESS
QUALITY BURN IN
CONTROL

PRODUCTION RELIABILITY
QUALITY TEST
CHECK

TECHNICAL WORK
DATA SHEET INSTRUCTION

IPQC
CHECKSHEET